Danfoss PVG 120 Service guide

MAKING MODERN LIVING POSSIBLE

Service Manual

Proportional Valve Group

PVG 120

powersolutions.danfoss.com

Service Manual	PVG 120 Proportional Valve Group

Revision history	Table of revisions
	Date		Changed	Rev
	May 2014		Converted to Danfoss layout – DITA CMS, major revision	JA
	Jan 2012		Pos. 3 change	ID
	Feb 2011		Table on page 35 changed, layout changes - all pages	IC
	Feb 2010		Handles on drawings	IA
	Jan 2010		Japan location	HC

2	520L0247 • Rev JA • May 2014

Service Manual	PVG 120 Proportional Valve Group
Contents
PVG 120 service parts exploded view
PVG 120 sectional view
Safety in application
	Control system example................................................................................................................................................................	8
	Examples of wiring block diagram.....................................................................................................................................	10
Identification
	Identification ...................................................................................................................................................................................	12
Installation
	Installation and plug orientation..............................................................................................................................................	13
	Connection, PVP, Pump Side Module.....................................................................................................................................	13
	Oil flow direction............................................................................................................................................................................	14
	Tightening Torques.......................................................................................................................................................................	14
	PVM, Lever Positions.....................................................................................................................................................................	16
	Setting of max. flow......................................................................................................................................................................	16
	Pressure Setting..............................................................................................................................................................................	17
	PVP, LS Relief Valve Pressure Setting.................................................................................................................................	17
	PVB, LS Relief Valve Pressure Setting.................................................................................................................................	17
	Option, Oil Flow Direction and Setting of max Flow.........................................................................................................	18
	Installation of PVE..........................................................................................................................................................................	18
	Bleeding.............................................................................................................................................................................................	20
	PVPE/PVH relief valves.................................................................................................................................................................	20
	PVPH and LS connections...........................................................................................................................................................	21
	PVPE technical data.......................................................................................................................................................................	21
	Connection PVPE............................................................................................................................................................................	22
PVP
	PVP, Pump Side Module..............................................................................................................................................................	23
	PVPD, PVPH, PVPE, Accessories for PVP.................................................................................................................................	25
PVLP / PVLA
	PVLP / PVLA, Shock and Suction Valve Port A/B.................................................................................................................	27
PVBP, PVBR, PVBC, PVBU
	PVBP, PVBR, PVBC, PVBU Accessories for PVB......................................................................................................................	29
PVM
	PVM, Mechanical Activating Module......................................................................................................................................	31
PVMD and PVH
	PVMD, Cover for PVM and PVH, Hydraulic Activation......................................................................................................	33
PVGI
	PVGI, Interface for PVG 120 and PVG 32................................................................................................................................	34
PVEH and PVEO
	PVEH and PVEO, Electrical Activating Module, ON-OFF...................................................................................................	35
PVT
	PVT, Tank Side Module – Upper Part.......................................................................................................................................	37
	PVT, Tank Side Module – Lower Part.......................................................................................................................................	39
PVAS and PVGI
	PVGI, Assembly Kit.........................................................................................................................................................................	41
	PVAS, Assembly Kit........................................................................................................................................................................	41
	Asssembly sequence...............................................................................................................................................................	41
Set of seals
	Set of Seals .......................................................................................................................................................................................	43
PVG 120 Modules Selection Chart
	PVG 120 module selection chart..............................................................................................................................................	44
Order specification

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Service Manual	PVG 120 Proportional Valve Group

Contents

Ordering of modules for oil flow exceeding 180 l/min [47.6 US gal/min].................................................................	48
Order Form.......................................................................................................................................................................................	48
Reordering...................................................................................................................................................................................	49

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	Service Manual	PVG 120 Proportional Valve Group
	PVG 120 service parts exploded view
	PVG 120 service parts exploded view
			13
			14
			10
			3
		9	11
		3	12
		8	4
		3
		7	5
		3
			6
		4	5
		1
	2		6
		5
			6
	14	5
		6	V310144.A

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Service Manual	PVG 120 Proportional Valve Group

PVG 120 sectional view

PVG 120 sectional view

X-X

10

11

12

11

4

pma

T	P	T
X X

P

A

1

9 2 A

B

13
T	P	T
3

LS

A 7 5

1 B 8

P	B
	13
	T	P	T
	3

6 5

V310100.A

Legend:
1	– Main spool	7	– Shock and suction valve PVLP
2	– Pressure adjustment spool in PVP	8	– Suction valve PVLA
3	– Shuttle valve	9	– Orifice, closed center PVP; Plug, open center PVP
4	– Pressure relief valve in PVP	10		– LS connection
5	– Pressure compensator in PVB	11		– Orifice, open center PVP
6	– LS pressure relief valve in PVB	12		– Plug, closed center PVP

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Service Manual	PVG 120 Proportional Valve Group

Safety in application

All makes and all types of control valves (incl. proportional valves) can fail, thus the necessary protection against the serious consequences of function failure should always be built into the system. For each application an assessment should be made for the consequences of pressure failure and uncontrolled or blocked movements.

To determine the degree of protection that is required to be built into the application, system tools such an FMEA (Failure Mode and Effect Analysis) and Hazard and Risk Analysis can be used.

FMEA – IEC EN 61508

FMEA (Failure Mode and Effect Analysis) is a tool used for analyzing potential risks. This analytical technique is utilized to define, identify, and prioritize the elimination or reduction of known and/or potential failures from a given system before it is released for production. Please refer to IEC FMEA Standard 61508.

Hazard and risk analysis ISO 12100-1 / 14121

This analysis is a tool used in new applications as it will indicate whether there are special safety considerations to be met according to the machine directives EN 13849. Dependent on the determined levels conformity this analysis will detirmine if any extra requirements for the product design, development process, production process or maintenance, i.e. the complete product life cycle.

W Warning

All makes/brands and types of directional control valves – inclusive proportional valves – can fail and cause serious damage. It is therefore important to analyze all aspects of the application.

Because the proportional valves are used in many different operation conditions and applications,

the manufacturer of the application is alone responsible for making the final selection of the products – and assuring that all performance, safety and warning requirements of the application are met.

The process of choosing the control system – and safety levels – is governed by the machine directives

EN 13849 (Safety related requirements for control systems).

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Service Manual	PVG 120 Proportional Valve Group

Safety in application

Control system example

Example of a control system for manlift using PVE Fault monitoring input signals and signals from external sensors to ensure the PLUS+1® main controllers correct function of the manlift.

Legend:

1 – Main power supply

2 – Emergency stop/man present switch

3 – HMI/Joystick control

4 – Movement detection sensors

5 – Main controller

6 – PVG control valve

7 – Hydraulic deactivation

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Service Manual	PVG 120 Proportional Valve Group

Safety in application

Electrical block diagram for the above illustration

W Warning

It is the responsibility of the equipment manufacturer that the control system incorporated in the machine is declared as being in conformity with the relevant machine directives.

PVG 32 – mainly used in system with fixed displacement pumps:

•PVSK, commonly used in crane application - full flow dump

•PVPX, LS dump to tank

PVG 100 – alternative LS dump or pilot supply disconnect:

•PVPP, pilot oil supply shut off

•External cartridge valve connecting LS pressure or main pressure to tank

PVG 120 – pump disconnect / block for variable pumps:

•PVPE, full flow dump for the PVG 120

•External cartridge valve connecting LS pressure to tank

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Service Manual	PVG 120 Proportional Valve Group

Safety in application

Examples of wiring block diagram

Example of a typical wiring block diagram using PVEH with neutral power off switch and fault monitoring output for hydraulic deactivation.

Emergency		Man present
A	stop	switch
PVE 1	Neutral detection / Supply control						PVEH
C		1)					with AMP
	signal	OFF					connector
	≠						US
		Delay
	neutral						UDC2
						B	Error
PVE 2	Neutral detection / Supply control						PVEH
C		1)					with AMP
	signal	OFF					connector
	≠						US
		Delay
	neutral						UDC2
						B	Error
			E1		E2
			2)	Alarm
				logic
					Output
		<![if ! IE]> <![endif]>OR	3) Memory
				<![if ! IE]> <![endif]>AND	high=on
					low=off
		Fault detection output				D	Hydraulic
							deactivation
							P301 318

A– Emergency stop / man present switch B– PVE Fault monitoring signals

C– Neutral signal detection. D– Hydraulic deactivation

System Control Logic e.g. PLUS+1® for signal monitoring and triggering signal for deactivation of the hydraulic system.

W Warning

It is the responsibility of the equipment manufacturer that the control system incorporated in the machine is declared as being in conformity with the relevant machine directives.

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Service Manual	PVG 120 Proportional Valve Group

Safety in application

Example of fault monitoring for deactivation of the hydraulic system with extra fault inputs using the PVE’s with DI (Direction Indication) function.

Emergency			Man present
	Stop		switch
PVE 1	Neutral detection / Supply control						PVEH-DI
			1)				AMP supply
	signal		OFF				connector
	≠						US
			Delay
	neutral						UDC2
							Error
							PVEH-DI
							AMP connector
	DI-B	2)	Fault detection				DI-A
			3)	4)			DI-B
	DI-A	DI	Output Delay	Memory			Error
	US	Logic
PVE 2	Neutral detection / Supply control						PVEH-DI
			1)				AMP supply
	signal		OFF				connector
	≠						US
			Delay
	neutral						UDC2
							Error
							PVEH-DI
							AMP connector
		2)	Fault detection				DI-A
	DI-B
			3)	4)
	DI-A	DI	Output Delay	Memory			Error
	US	Logic
					<![if ! IE]> <![endif]>OR
					<![if ! IE]> <![endif]>AND	high=on
						low=off
					Fault detection output		Hydraulic
							deactivation
							P301 319

System Control Logic e.g. PLUS+1® for signal monitoring and triggering signal for deactivation of the hydraulic system.

W Warning

It is the responsibility of the equipment manufacturer that the control system incorporated in the machine is declared as being in conformity with the relevant machine directives.

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Service Manual	PVG 120 Proportional Valve Group

Identification

Identification

PVG 120 Identification

PVB

PVM

PVT

PVM

PVP

PVEH	G
	P

PVEO

	MA	S
		E
F		C
		D

PVH

PVMD

V310156.A

C:PVG – number, week and year of installation

D:PVP – pressure setting

E:PVP – number, week, year and day manufacturing, issue and series No.

F:PVB – A-Port, number, week, year and day manufacturing, issue and series No.

G:PVT – week and year of manufacturing

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Service Manual	PVG 120 Proportional Valve Group

Installation

Installation and plug orientation

Installation Dimensions

<![if ! IE]>

<![endif]>190 [7.48]*

<![if ! IE]>

<![endif]>100 [3.94]*

* Room for dismantling

60 Nm	60 Nm	<![if ! IE]> <![endif]>[7.48]*
[530 lbf•in]	[530 lbf•in]	<![if ! IE]> <![endif]>190
	4xM12x18
	[4x7/16-14UNCx0.7]
<![if ! IE]> <![endif]>105 [4.13]
	L	<![if ! IE]> <![endif]>100 [3.94]*
		V310179.A

Module of PVB	1	2	3	4	5	6	7	8
L mm	168	235	302	369	436	503	570	637
L in	6.61	9.25	11.88	14.53	17.17	19.80	22.44	25.08

Connection, PVP, Pump Side Module

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Service Manual	PVG 120 Proportional Valve Group

Installation

Oil flow direction

Mechanical / electrical actuation

Mechanical / hydraulic actuation

A P B A

B P A B

PB PA

P

V310169.A

V310163.A

A P B A P A

B B

PB PA

P

V310162.A

V310170.A

Tightening Torques

Max. tightening torques – Connection Threads Type G (ISO 228/1)

	Max. tightening torques
Ports	PA, PB	MA	LS, LX, PP
Sealing thread	G 1/4	G 1/4	G 3/8
With steel washer	35 N•m [310 lbf·in]	40 N•m [350 lbf·in]	60 N•m [530 lbf·in]
With cooper washer	30 N•m [270 lbf·in]	20 N•m [180 lbf·in]	35 N•m [310 lbf·in]
With aluminium washer	30 N•m [270 lbf.in]	30 N•m [270 lbf.in]	40 N•m [350 lbf·in]
With cutting edge	35 N•m [310 lbf.in]	40 N•m [350 lbf.in]	60 N•m [530 lbf·in]

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Service Manual	PVG 120 Proportional Valve Group
Installation
Max. tightening torques – Mounting Threads in SAE J 518c Flanges
Port		Size			Threads			Tightening torque
P		1 in			M12, 18 deep			68 N•m
					7/16 - 14 UNC 0.7” deep			[600 lbf·in]
A/B		3/4 in			M10, 17 deep			45 N•m
					3/8 - 16 UNC 0.7” deep			[400 lbf·in]
T		1 in			M10, 17 deep			45 N•m
					3/8 - 16 UNC 0.7” deep			[400 lbf·in]
Max. tightening torques – UN and UNF Connection Threads – O-ring Boss Port
				Max. tightening torques
Ports	P		A/B	T		PA/PB	MA		LS, LX, PP
Sealing	1 5/16 in-12 UN		1 1/16 in-12 UN	1 5/16 in-12 UN		½ in-20 UNF	½ in-20 UNF		¾ in-20 UNF
/Thread
O-ring	160 N•m		120 N•m	160 N•m		30 N•m	30 N•m		60 N•m
	[1410 in•lbs]		[1060 in•lbs]	[1410 in•lbs]		[270 in•lbs]	[270 in•lbs]		[530 in•lbs]

Ports identification

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Service Manual	PVG 120 Proportional Valve Group

Installation

PVM, Lever Positions

Base with an angle of 37.5°

	19
	.5˚
	19
	.5˚
37	67
.5˚	.5˚
	97
	.5˚
	127
	.
	5˚
	157
	.
	5˚
	187
	.
	5˚

Base with an angle of 22.5°

19.5˚

22.5˚	52
	.5˚

19 .5˚

82 .5˚ 112

. 5˚

142

. 5˚

172

. 5˚

V310018.A

V310014.A

Setting of max. flow

Setting of Max. Flow

	Q max.A
Q max.B	Q max.	Q max.
	A	B
		T
	LX	PP

3[0.12]
Q max.B		-	8 Nm
		+
Q max.A	-		[70 lbf in]
	+		10[0.39]
			V310101.A

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